Part comprising a structure and a shape memory alloy element

ABSTRACT

A part includes a structure and at least one shape memory alloy element that is prestressed and embedded at least in part within said structure. The shape memory alloy is suitable for dissipating the mechanical energy of said structure when it vibrates in a given frequency band.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 13/497,134filed Mar. 20, 2012, the entire contents of which is incorporated hereinby reference. U.S. application Ser. No. 13/497,134 is a national stageof Application No. PCT/FR10/051840 filed Sep. 3, 2010, and claims thebenefit of priority from French Application No. 09 56469 filed Sep. 21,2009.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a part including a structure.

2. Description of the Related Art

In certain applications, a structure is subjected to aerodynamicstresses caused by the flow of a fluid, e.g. air, around said structure.This applies for a structure that is a part of an aviation turbineengine, e.g. a fan blade. These stresses can cause the structure tovibrate. Such a structure also possesses its own vibration modesassociated with its mechanical properties (essentially its distributionsof stiffness and mass). Unstable coupling can then become establishedbetween the vibration generated in the structure by the aerodynamicstress, and the vibratory characteristics of the structure, by feedbackbetween the structure and the fluid that flows around it. This couplingphenomenon is known as “flutter”. Whether or not flutter appears in astructure that is subjected to aerodynamic stresses depends on thebalance of the sum of two energies: the aerodynamic energy E_(A) and themechanical dissipation energy of the structure E_(M).

The aerodynamic energy E_(A) is the energy transmitted by the fluid tothe structure as a result of flowing around it.

The mechanical dissipation energy of the structure E_(M) is the energythat is dissipated mechanically by the structure. This dissipationdepends on the intrinsic mechanical properties of the structure. For astructure made of composite material, these mechanical properties dependon the nature of the materials making up the composite structure, and onthe internal architecture of the structure, i.e. on the arrangementbetween the various materials that make it up. This arrangement mayexist at one or more scales: mesoscopic (short/long fibers, particles),macroscopic (weaving, braiding, layers/plies).

There is a risk of flutter in the structure when (−E_(A))>E_(M).

Flutter is a phenomenon that is undesirable in a structure since itcauses the structure to enter into resonant modes in which vibrationamplitudes within the structure increase in uncontrolled manner, andthat can lead to the structure being destroyed.

The present invention seeks to remedy that drawback.

BRIEF SUMMARY OF THE INVENTION

The invention seeks to propose a part comprising a structure, e.g. acomposite structure, in which vibration levels are decreased for a widevariety of free stresses (flutter) or forced stresses of asynchronous,synchronous, or transient type.

This object is achieved by the fact that the part includes at least oneshape memory alloy element that is prestressed and embedded at least inpart within said structure, said shape memory alloy being suitable fordissipating the mechanical energy of said structure when it vibrates ina given frequency band.

By means of these arrangements, the shape memory alloy (SMA) element(s)confer(s) on the structure an internal function of damping the vibrationto which the structure is subjected. This increases the mechanicaldissipation energy E_(M) of the structure, and thus decreases the riskof the structure fluttering.

The invention also provides a method of fabricating a composite materialstructure having a shape memory alloy element within it, the structurebeing made up of a plurality of substructures.

According to the invention, the method is characterized by the followingsteps:

providing a plurality of sub-structures;

applying prestress to said shape memory alloy element;

placing said at least one shape memory alloy element on one of saidsub-structures;

covering said at least one shape memory alloy element at least in partby another one of said sub-structures;

fastening together said shape memory alloy element and said structure,said sub-structures being selected from a group comprising a laminate ofunidirectional plies, a woven composite, a braided composite, a uniformmaterial, a film type covering, and a layer-of-paint type covering; andreleasing said prestress.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention can be better understood and its advantages appear betteron reading the following detailed description of an embodiment given byway of non-limiting example. The description refers to the accompanyingdrawings, in which:

FIG. 1 shows the behavior of a shape memory alloy used in a structure ofthe invention;

FIG. 2 is a diagrammatic section view of a part of the invention with acomposite structure including plies;

FIG. 3A is a diagram of a part of the invention with a compositestructure including braided fibers;

FIG. 3B is a diagram showing a part of the invention with a compositestructure including woven fibers;

FIG. 4 is a diagrammatic section view of a part of the invention with astructure comprising a plurality of composite sub-structures;

FIG. 5 shows a fan blade of the invention in which the SMA wires areoriented and positioned in its zones of maximum deformation; and

FIG. 6 shows one example of a behavior relationship for an SMA materialwith prestress.

DETAILED DESCRIPTION OF THE INVENTION

Consideration is given to a structure that may be made of a compositematerial, or else of a uniform material, including of an alloy. Thestructure is nevertheless not itself made of a shape memory alloy.

In the present application, the term “composite material structure” isused to mean a structure made up of at least two materials havingmechanical properties that are dissimilar.

For example, one of the materials is reinforcement and is embedded inthe other material that constitutes a matrix. The arrangement betweenthe reinforcement and the matrix may exist at one or more scales:mesoscopic (continuous fiber forming a unidirectional ply, or shortfibers or particles in a matrix); or macroscopic (weaving or braidingfibers in a matrix, superposing layers made up of woven/braided fibersor plies).

The composite material structure may also be constituted by a core madeof uniform material situated inside an envelope made of some otheruniform material or of composite material. The core may be of a materialthat is less rigid than the material of the envelope, e.g. a core may bemade of foam.

The composite material structure may also be a structure made up of twomaterials, one of the materials being a covering that covers the othermaterial, at least in part. By way of example, the covering may be afilm, which may serve to provide protection against erosion or againstultraviolet (UV) radiation, or a paint, which may serve to provideprotection against UV radiation. In particular, the covering may beconstituted by a film, e.g. of polyurethane, formed on the pressure sideface of the part, and a paint on the suction side face. The othermaterial may be a uniform material or a composite material.

The invention is described below for circumstances in which thestructure is a composite material structure.

When a composite material structure, in particular a structure ofelongate shape, is placed in a fluid flow, e.g. a flow of air, theinteraction between the flow and the structure may give rise tovibration within the part. For certain ranges of parameters, whichparameters include the physical properties and the flow speed of thefluid, the mechanical properties of the materials making up thestructure, and the internal structure of the structure (shape andarrangement of its various materials), it can happen that flutterbecomes established in the part, i.e. a regime of undesirable vibration,as explained above. Such flutter can lead to damage and destruction ofthe structure.

In order to prevent flutter, the inventors insert within the structureat least one element made of shape memory alloy (SMA), in particularwires or sheets, which element is embedded at least in part inside thestructure.

SMAs presents non-linear behavior under mechanical stress, with thisbeing due to a reversible austenite/martensite phase change taking placewithin the crystal lattice of the SMA. Since this feature of SMAs isitself known, only the main principles are outlined below.

As shown in FIG. 1, the stress-strain curve σ(ε) for an SMA follows acertain path when stress a is applied (curve 1) and a different pathwhen the stress is relaxed (curve 2). The structure returns to itsinitial shape (the strain ε is elastic), however the structuredissipates energy internally during this cycle of change (hysteresiseffect). This energy is equal to the area that lies between curve 1 andcurve 2.

Thus, when an SMA is subjected to repeated stresses, e.g. because ofvibration, it dissipates energy by hysteresis on each stress cycle.

By inserting SMA elements in a structure, it is thus possible bydissipating energy in hysteresis to reduce undesirable vibration of thestructure (which amounts to increasing the mechanical dissipation energyof the structure E_(M)), thereby reducing the risk of flutter in thestructure.

The SMA elements are embedded, in full or in part, within the structureso that the deformation of the structure is transmitted to saidelements, in order to ensure that the elements take up the stresses towhich the structure is subjected and thus perform their damping role.Advantageously, there is good adhesion between the SMA elements and thezones of the structure with which these elements are in contact, so thatthe deformations of the structure are transmitted more effectively tothe elements.

The SMA elements are also prestressed, i.e. they are subjected to acertain level of stress on being inserted into the composite structure,with this applied stress being removed only after the elements havebonded to the surrounding structure, such that a certain amount ofstress remains in the elements when the structure is at rest. The effectof this prestress is to shift the hysteresis cycle (see FIG. 1) of anSMA element to a range of stresses that is different from that of anon-prestressed element. FIG. 6 shows an example of a behaviorrelationship (stress-strain σ(ε)) of an SMA material with prestress,showing the offset hysteresis cycle. The stress σ is expressed inmegapascals (MPa) (i.e. 10⁶ pascals), and the strain ε in %.

The prestress serves to maximize the damping function of the SMAelements so that these elements are active at the maximum stressesgenerated during flutter.

For example, the SMA element(s) may be prestressed in tension.

Thus, each point of the SMA element is subjected to tension stress, withthis stress not necessarily being uniform within the SMA element.

By way of example, this prestress is applied mechanically by increasingthe distance between two opposite ends of the SMA element. Thus, a firstend of the element is held stationary, and the opposite other end ismoved away from the first end. Alternatively, the two opposite ends ofthe element are moved apart. Under such circumstances, and when theembodiment is a wire, the ends are the longitudinal ends of the wire.

The prestress may also be applied thermally by heating the SMAtemperature to a temperature higher than the temperature of thesurrounding structure.

Under such circumstances, the heating of the SMA element (e.g. byplacing it in an oven) causes the element to expand, and thus generatesa tension prestress field in the element.

The element may also be heated by causing an electric current to flowalong the element, with this flow giving rise to heating of the elementby the Joule effect.

Depending on the architecture of the composite material structure withinwhich the SMA element(s) is/are placed, depending on its shape, anddepending on the places where insertion takes place, the method wherebythe elements are inserted may vary.

When the structure is made up of a plurality of sub-structures,prestress is applied to the shape memory alloy element(s), the shapememory alloy element(s) is/are put into place on one of thesub-structures, the shape memory alloy element(s) is/are covered atleast in part by another one of the sub-structures, the shape memoryalloy element(s) and the structure are fastened together, and then theprestress is released.

The shape memory alloy element(s) are thus placed at the interfacebetween the sub-structures.

Thus, when the composite material of the structure comprises a laminateof unidirectional plies, the SMA element(s) 10 may be placed between theplies 20, as shown in FIG. 2. Thus, after one of the plies has been putinto place, one or more SMA elements are put into place on the ply, thenthe assembly is covered by another ply, which may be oriented in thesame direction or in a different direction. These SMA elements maycomprise one or more wires or a sheet. Thereafter the assembly ispolymerized so as to form a solid block within which the SMA element(s)is/are embedded.

As shown in FIG. 3A, one or more wires (and/or a sheet) of SMA 10 may beinserted between a first braid 21 made during a first pass of braidingthe preform, and a second braid 22 made during a second braiding passprior to densifying the preform (with densification being performed forexample by infusion, injection, or chemical vapor infiltration).

In general, the sub-structures are selected from a group comprising alaminate of unidirectional plies, a woven composite, a braidedcomposite, a uniform material, a film type covering, or a covering ofthe layer-of-paint type.

Thus, when the structure is made up of a sub-structure covered at leastin part in a covering, the SMA element(s) may be placed on thesub-structure and covered, at least in part, by the covering, which maybe a film, or a layer of paint.

When the composite material of the structure comprises a preform made byweaving or braiding fibers, the SMA element(s) may be inserted withinthe preform.

As shown in FIG. 3B, one or more SMA wires 10 may be prestressed andthen inserted directly into the woven three-dimensional (3D) preform 30before the preform and the SMA wires are densified. The preform may alsobe a two-dimensional (2D) woven preform.

The preform is then densified. The prestress is released afterdensification.

Alternatively, the preform may be made directly with woven or braidedfibers including at least one that is a shape memory alloy wire that haspreviously been prestressed. The preform as made in this way is thendensified, after which the prestress is released.

FIG. 4 shows a situation in which the SMA wires 10 are placed within apropeller blade 40 at the interface between the strut 42 of compositematerial and a foam core 41, at the interface between the envelope 44 ofcomposite material and a foam body 43, and at the interface between theenvelope 44 of composite material and the strut 42 of compositematerial.

The composite structure in which the SMA element(s) is/are inserted maybe a part for an aviation turbine engine. For example, the part may be amoving blade or a vane for a fan, a moving blade or a vane for acompressor or for a low pressure (LP) turbine, or for a high pressure(HP) turbine. The part may also be a propeller blade or a turbine enginecasing.

SMA elements may be placed in a plurality of zones within the structure.

Advantageously, the SMA element(s) is/are placed in one or more zones inwhich the composite structure is subjected to high levels ofdeformation, with the element(s) being oriented in the direction ofmaximum deformation. These zones are densified beforehand in knownmanner by modeling, e.g. using finite elements, or by testing. Thus, thevibration-damping effectiveness of the SMA elements is optimized. FIG. 5shows a fan blade 50 in which SMA wires 10 (shown as if the blade weretransparent) are oriented and positioned in the zones of maximumdeformation within the structure, and by way of example in particular:

near the root of the blade, parallel to its leading edge; and

near the tip of the blade parallel to the end face of the blade tip.

The SMA elements may also be sheets, with the damping effect of the SMAelements then taking place in any direction within the plane of thesheet.

While being embedded in the composite structure, the SMA elements may besituated close to the surface of the structure. Such a positionmaximizes the deformation of the SMA elements.

The composite materials used in the composite structure may for examplebe organic matrix composites, or high temperature composites (e.g.composite having a ceramic or a metal matrix). Ideally, the SMAs areselected as a function of the operating temperature of the compositestructure, such that the operating temperature lies within thetemperature range in which the hysteresis effect (FIG. 1) occurs, whichtemperature range is specific to the SMA in question.

The SMAs used in the composite structure may for example be alloys ofNi—Ti, or Ni—Ti—Hf, or Ni—Ti—Pd, or Ti—Au—Cu, or Hf—Pd, or Ru—Nb, orRu—Ta.

1. (canceled)
 2. A fabrication method for fabricating a compositematerial structure with at least one shape memory alloy element withinsaid structure, said structure being made up of a plurality ofsub-structures, said method comprising: providing a plurality ofsub-structures; applying prestress to said shape memory alloy element;placing said at least one shape memory alloy element on one of saidsub-structures; covering said at least one shape memory alloy element atleast in part by another one of said sub-structures; fastening togethersaid shape memory alloy element and said structure, said sub-structuresbeing selected from a group comprising a laminate of unidirectionalplies, a woven composite, a braided composite, a uniform material, afilm type covering, and a layer-of-paint type covering; and releasingsaid prestress, wherein said structure is a part for an aviation turbineengine.
 3. The fabrication method according to claim 2, wherein saidprestress is applied mechanically by increasing the distance between twoopposite ends of said shape memory alloy element.
 4. The fabricationmethod according to claim 2, wherein said prestress is applied thermallyby heating said shape memory alloy elements to a temperature higher thanthe temperature of said structure.
 5. A fabrication method according toclaim 4, wherein said shape memory alloy element is heated by causing anelectric current to flow along said element.
 6. A fabrication method forfabricating a fiber structure with at least one shape memory alloyelement within said structure, the method comprising: providing apreform of woven or braided fibers; applying prestress to said shapememory alloy element; inserting said at least one shape memory alloyelement within said preform; densifying said preform and said at leastone shape memory alloy element; and releasing said prestress, whereinsaid structure is a part for an aviation turbine engine, and whereinsaid structure is made up of a plurality of sub-structures, said atleast one shape memory alloy element being placed in at least one ofinterfaces between said sub-structures.